Multi-Layer Golf Ball with Bladder Core

ABSTRACT

The present disclosure is directed to a golf ball and a method for manufacturing a golf ball including a bladder core. In at least one embodiment, the bladder core includes an ethyl vinyl alcohol copolymer layer combined with multiple layers of thermoplastic polyurethane or other material to prevent leakage. In addition, it is contemplated that the bladder core may include a one-way valve for adjusting the pressure of a fluid within the bladder core to produce different performance characteristics.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/408,209 filed Feb. 29, 2012, which is herebyincorporated herein by reference in its entirety.

BACKGROUND

The present disclosure relates generally to a multi-layer golf ballhaving a bladder core.

Golf is a sport that enjoys wide popularity around the world and isplayed by golfers of all ages, from young to old. To aid and improvetheir performance, golfers continually search for and adopt the best andnewest equipment, including golf clubs, golf balls, apparel and trainingdevices. To that end, there are many equipment choices available,including a number of different golf balls brands and types, eachdesigned to exhibit certain characteristics in play.

Golf balls constructions have generally included a core made from aresilient material and a cover made from a more durable material, suchas synthetic resin. The core is typically made from rubber or a similarmaterial and typically has a wound or solid construction. Intermediatelayers made from a variety of materials may be provided between the coreand cover to vary the perceived feel when the ball is hit, or to exhibitcertain performance characteristics in play. Typically, golfers useballs with constructions that achieve their desired feel andperformance.

The present disclosure is directed to a golf ball and a method formanufacturing a golf ball including a bladder core.

SUMMARY

The disclosure provides a golf ball with a bladder forming the innercore. The bladder includes walls made of thin sheets of polymericmaterials, where the walls define an interior space. The interior spaceof the bladder is, in some embodiments, filled with a fluid, such as apressurized gas or a liquid. The materials used to form the thin sheetsare selected so as to inhibit the bleeding of the fluid through thewalls of the bladder. In one aspect, where the gas is air or nitrogen,for example, the material may include ethylene-vinyl alcohol copolymer.The ethylene-vinyl alcohol copolymer may be used in conjunction withsheets of thermoplastic polyurethane (TPU), so that the walls of thebladder are durable, flexible, readily manufactured, and cost-effective.

In one aspect, the disclosure provides a golf ball having a core, anintermediate layer substantially surrounding the core, and an outerlayer substantially surrounding the intermediate layer, wherein theouter layer includes a plurality of dimples. According to aspectsdescribed herein, the core of the golf ball comprises a bladder formedfrom an ethyl vinyl alcohol copolymer layer and contains a pressurizedfluid.

In another aspect, the disclosure provides a golf ball having a core, anintermediate layer substantially surrounding the core, and an outerlayer substantially surrounding the intermediate layer, wherein theouter layer includes a plurality of dimples. According to aspectsdescribed herein, the core of the golf ball comprises a bladder, thebladder formed from a plurality of bladder panels joined together toform a sealed structure that encloses a pressurized fluid,

In yet another aspect, the disclosure provides a method of manufacturinga golf ball the steps of: placing a plurality of flattened polymerelements in a restriction structure; bonding the plurality of flattenedpolymer elements together to define seams in a bladder; inflating thebladder to take on the shape of the restriction structure; injecting apressurized fluid into the bladder and sealing the bladder; molding arubber composition around the bladder to form an intermediate layer; andapplying a cover layer.

Other systems, methods, features and advantages of the presentdisclosure will be, or will become, apparent to one of ordinary skill inthe art upon examination of the following figures and detaileddescription. It is intended that all such additional systems, methods,features and advantages be included within this description and thissummary, be within the scope of the disclosure, and be protected by thefollowing claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles disclosed herein.

Moreover, in the figures, like reference numerals designatecorresponding parts throughout the different views.

FIG. 1 is a perspective view of a golf ball having a bladder accordingto one or more embodiments set forth herein;

FIG. 2 is a cross-sectional view of the golf ball depicted in FIG. 1, asdefined by section line 2 in FIG. 1, according to an embodiment setforth herein;

FIG. 3 is a perspective view of a mold for forming a bladder accordingto an embodiment set forth herein;

FIG. 4 is an exploded perspective view of the mold according to anembodiment set forth herein;

FIGS. 5A-5C are schematic perspective views of a manufacturing processfor forming a bladder according to an embodiment set forth herein;

FIG. 6 is a perspective view of the bladder and residual portions ofpolymer sheets forming the bladder following the manufacturing processaccording to an embodiment set forth herein:

FIG. 7 is a perspective view of the bladder following the manufacturingprocess according to an embodiment set forth herein;

FIG. 8 is a perspective view of a golf ball having a bladder accordingto an additional embodiment set forth herein;

FIG. 9 is a cross-sectional view of the golf ball depicted in FIG. 8, asdefined by section line 9 in FIG. 8, according to an additionalembodiment set forth herein;

FIGS. 10A-10B are schematic perspective views of a manufacturing processfor forming a bladder according to an additional embodiment set forthherein;

FIG. 11 is a perspective view of the bladder and residual portions ofpolymer sheets forming the bladder following the manufacturing processaccording to an additional embodiment set forth herein;

FIG. 12 is a perspective view of the bladder following the manufacturingprocess according to an additional embodiment set forth herein; and

FIG. 13 is a cross-sectional view of the golf ball depicted in FIG. 1,as defined by section line 2 in FIG. 1, according to yet anotherembodiment set forth herein.

DETAILED DESCRIPTION

The present disclosure relates to a golf ball incorporating a bladdercore, as well as a method for manufacturing a bladder core for a golfball.

The disclosure provides a golf ball with a bladder forming the innercore. The bladder includes walls made of thin sheets of polymericmaterials, where the walls define an interior space. The interior spaceof the bladder is, in some embodiments, filled with a fluid, such as apressurized gas or a liquid. The materials used to form the thin sheetsare selected so as to inhibit the bleeding of the fluid through thewalls of the bladder. In one aspect, where the gas is air or nitrogen,for example_(;) the material may include ethylene-vinyl alcoholcopolymer. The ethylene-vinyl alcohol copolymer may be used inconjunction with sheets of thermoplastic polyurethane (TPU), so that thewalls of the bladder are durable, flexible, readily manufactured, andcost-effective.

The performance of a golf ball may be driven by a number of factorsincluding, but not limited to, the materials that are used to make theball, the number of layers within the ball, the hardness and/or densityof the material that makes up each layer, the thickness of each layer,and the way the layers are put together to form the ball. Each of thesefeatures may affect the perceived feel of the ball when it is struck bythe club face as well as the performance of the ball in flight and ontouchdown, including the velocity and resulting spin achieved by theball in flight. For example, solid golf balls with multiple internallayers may create more spin as the ball is launched from the face of aclub. Other features of the core may create less spin on the ballcausing increased velocity and distance when the ball is hit. Golferstypically select balls based on the desired play characteristics of theball and the feel of the ball, often based upon the golfer's skill leveland personal preferences.

According to embodiments set forth herein, a golf ball may include aprovision to lighten the core layer of the ball. As those skilled in theart will readily appreciate, a golf ball containing a core that is lightrelative to the other layers in the ball presents a number of benefits.One benefit known in the art is that a lighter core shifts the moment ofinertia (MOI) of the ball to the perimeter of the ball. In shifting theMOI to the perimeter, the spin rate off the club head upon impact isalso reduced, allowing the ball to travel farther.

Another well-known result of a lighter core ball is a lower compressionrate. As is known in the art, the compression rate of a ball is theexpression (i.e., a number typically in the range of 0 to 200) of howmuch deflection a ball undergoes when it is subjected to a compressiveload, such as a golf club. In other words, as a golf ball is hit, thespherical shape will become more hemispherical. The higher thecompression rate of the ball, the less compression the ball will displaywhen hit. When a ball has a soft and/or lighter core, the ball tends tobe more easily compressed, allowing golfers with a slower club-headspeed to take advantage of the spring effect that results fromcompression of the ball, and, thereby to achieve more total distancefrom a shot.

Yet another benefit of a golf ball with a lighter core results from acombination of the shift in the MOI to the perimeter with the lowercompression rate. In particular, the shift in the MOI (and the resultingreduction in spin rate) allows a golfer with a high club head speed tomaintain performance, while the lower compression rate of the ballallows for enhanced performance from a golfer with a lower club headspeed.

FIG. 1 depicts a golf ball 10, according to at least one embodimentdescribed herein. According to FIG. 1, golf ball 10 includes a coverlayer 20. Cover layer 20 may be covered in its entirety with a pluralityof dimples 24 to create an overall dimpled pattern, as is known in theart. Most golf balls in play today may look and feel very similar togolf ball 10 with exterior variations in color, markings on the ball,the dimple pattern, and the hardness of the cover layer. Internally,however, golf balls may exhibit a variety of features including multiplelayers made from a variety of materials.

As depicted in the cross-sectional view of golf ball 10 in FIG. 2, anembodiment of golf ball 10 exhibits a layered structure having (a) acover layer 20 that forms an exterior portion of golf ball 10, (b) anintermediate layer 30 located within cover layer 20, where cover layer20 substantially surrounds intermediate layer 30, and (c) an internalcore 40 that forms an interior portion of ball 10, where intermediatelayer 30 substantially surrounds internal core 40. As discussed in moredetail below, golf ball 10 may be varied to include additional layers ofvarying materials and varying hardnesses to achieve a desired playcharacteristic, such as a specific “feel” when the ball is hit or aspecific spin or velocity characteristic in flight.

As used herein, the term “cover layer” may be understood as theoutermost structural layers of a golf ball, not including any relativelythin finishing or coating layers. In the embodiment depicted in FIG. 2,cover layer 20 may include an outer cover 21 and inner cover layer 22.The outer cover 21 of cover layer 20 includes at least one dimple 24,and typically, a plurality of dimples 24, which affect the aerodynamicperformance of golf ball 10. Inner cover layer 22 may or may not bepresent.

Cover layer 20 may be made from a variety of materials known in the art.Outer cover 21 may be constructed from a variety of materials rangingfrom harder to softer, depending on the specific performancecharacteristics desired. For example, softer covers are generallyassociated with greater control, as golf ball 10 may be easier to spinwith a soft cover, which harder covers are generally associated withdurability. Inner cover layer 22 may be formed from a harder materialthan outer cover 21, thus adding protection to golf ball 10 facilitatingits durability. Inner cover 22 may also be a harder material than outercover 21 so that spin and control are maximized on iron shots, whichexperience softer outer cover 21, while also maximizing distance ondriver shots, which experience harder inner cover 22. Cover layers withdifferent hardnesses may also improve the feel of golf ball 10.Materials used for the outer cover 21 and inner cover layer 22 of coverlayer 20 may include any known golf ball cover materials, such as,synthetic resins, rubber compositions, and other polymers in a varietyof hardness levels.

In the embodiment depicted in FIG. 2, intermediate layer 30 covers andsubstantially encloses internal core 40. Intermediate layer 30 may haveany thickness. While the thickness of intermediate layer 30 willgenerally be dictated by the thickness of internal core 40 and theexistence of additional layers within the golf ball, in one embodiment,the thickness of intermediate layer may range from about 3 millimetersto about 11 millimeters. In some embodiments, the thickness ofintermediate layer 30 may be selected to ensure that golf ball 10 is aconforming golf ball, i.e., conforms to the USGA Rules of Golf.Intermediate layer 30 may be made from a variety of polymer and/orthermoset materials known in the art. In some embodiments, the thermosetmaterial may be a rubber composition using any rubber composition knownin the art.

According to at least one embodiment, internal core 40 is the innermostportion of golf ball 10 and may comprise a bladder 41 filled with a coresubstance 48, such as pressurized fluid. In other embodiments, coresubstance 48 could comprise a liquid or a gel. Similar to inflatablesport balls, such as a soccer ball or a volley ball, internal core 40may be formed from multiple malleable panels capable of beingthermo-formed and inflated during manufacturing. Such technology haspreviously been described in relation to inflatable sport balls in U.S.Patent Application Publication Number 2009/0325745, filed on Jun. 27,2008, U.S. patent application Ser. No. 13/101,026, filed on May 4, 2011,and U.S. patent application Ser. No. 13/101,041, filed on May 4, 2011,each of which is herein incorporated by reference in its entirety.

As described in greater detail below, the walls of bladder 41 may beconstructed from multiple panels (e.g., first panel 61 and second panel62 in FIG. 5A) bonded together to form seams. Further, each of firstpanel 61 and second panel 62 may be formed from a wide range of polymermaterials, selected in part on a material's resistance to the bleedingof air molecules through the material. One such suitable material isthermoplastic polyurethane. In addition to thermoplastic polyurethane,examples of polymer materials that may be suitable for the walls ofbladder 41 include urethane, polyester, polyester polyurethane, andpolyether polyurethane. The walls of bladder 41 may also be formed froma material that includes alternating layers of thermoplasticpolyurethane and ethylene-vinyl alcohol copolymer. in some embodiments,the walls of bladder 41 may be formed from multiple layers fusedtogether wherein a center layer is formed of ethylene.-vinyl alcoholcopolymer (EVOH), layers adjacent to the center layer are formed ofthermoplastic polyurethane (TPU).

In at least one embodiment, the walls of bladder 41 may be comprised ofseven layers fused together, as is depicted in the inset portion of FIG.2. In particular, bladder 41 may comprise one EVOH layer 46 in thecenter with multiple layers of TPU, upper TPU layers 42 and lower TPUlayers 44. EVOH layer 46 serves to prevent the molecules of gas enclosedwithin from escaping According to aspects described herein, each of EVOHlayer 46, upper TPU layers 42 and lower TPU layers 44 may comprise athin film such that the film thickness is in the range of about 5-10microns. In some embodiments, an additional EVA/Surlyn® film may beapplied over upper TPU layers 42 to improve adhesion between bladder 41and any adjacent layers, such as intermediate layer 30.

The number and order of the layers of EVOH and TPU of bladder 41 may bealtered as would be contemplated by a skilled artisan. Furthermore, itshould be understood that any of the multiple upper TPU layers 42 andlower TPU layers 44 in the depicted embodiment may be achieved by analternate thermoplastic polymer that is capable of being turned into afilm.

Bladder 41 may enclose a core substance 48, such as a fluid. If thefluid is a gas, the gas may be pressurized between zero andthree-hundred-fifty kilopascals (i.e., approximately fifty-one poundsper square inch) or more. In addition to air and nitrogen, the fluidcontained by bladder 41 may include octafluoropropane or be any of thegasses disclosed in U.S. Pat. No. 4,340,626 to Rudy, such ashexafluoroethane and sulfur hexafluoride, for example. Althoughdiscussed above as having a sealed and valve-less configuration, someconfigurations of bladder 41 may incorporate a valve that permitsadjustments to the pressure of the fluid, such as the embodimentdepicted in FIGS. 8-12 and described in more detail below.

A variety of manufacturing processes may be utilized for the bladder 40depicted in FIG. 2. As an example, a thermoforming process may formbladder 41 from a pair of polymer sheets that are molded to form firstbladder panel 61 and second bladder panel 62 (shown in FIGS. 5A-5C) andbonded to seal bladder 41 and define seam 64 (shown in FIG. 5C). Moreparticularly, the thermoforming process (a) imparts shape to one of thepolymer sheets in order to form a hemispherical or otherwise curvedstructure of one of first bladder panel 61 and second bladder panel 62,(b) imparts shape to another of the polymer sheets in order to form ahemispherical or otherwise curved structure of the other of firstbladder panel 61 or second bladder panel 62, and (c) forms seam 64 bybonding peripheries of the curved structures formed from the polymersheets. The thermoforming process may also involve sealing bladder 40 orincorporating an inflation tube 63 (shown in FIG. 5B) that permitsbladder 41 to be pressurized.

FIGS. 3 and 4 depict an exemplary mold 50 that may be used for thethermoforming process described above, according to at least oneembodiment. In particular, mold 50 having an upper mold portion 51 and alower mold portion 52 may be formed to define an internal cavity 53 withthe configuration of bladder 41, so that the inner surface of upper moldportion 51 and lower mold portion 52 are mold surfaces or restrictionsurfaces against which the polymer material of the walls of bladder 41are to be pressed to be shaped during the molding process. When uppermold portion 51 and lower mold portion 52 are joined together,therefore, internal cavity 53 has a generally spherical shape with theapproximate dimensions of bladder 41. Depending upon the degree to whichthe pressurization of bladder 41 induces the polymer material tostretch, internal cavity 53 may exhibit lesser volume or a lesserdiameter than bladder 41 in the pressurized state.

According to aspects set forth herein, mold 50 may be utilized to formbladder 41 from a pair of polymer sheets, first bladder panel 61 andsecond bladder panel 62. Initially, various conductive or radiativeheaters may be utilized to heat first bladder panel 61 and secondbladder panel 62. At elevated temperatures that depend upon the specificpolymer material utilized, first bladder panel 61 and second bladderpanel 62 soften or become more deformable, which facilitates shaping andbonding. Once heated, first bladder panel 61 and second bladder panel 62are positioned between upper mold portion 51 and lower mold portion 52,as depicted in FIG. 5A. In some manufacturing processes, a plurality ofconduits may extend through mold 50 in order to channel a heated liquid,such as water or oil, through mold 50, thereby raising the overalltemperature of mold 50. When first bladder panel 61 and second bladderpanel 62 are positioned within mold 50, heat may be transferred frommold 50 to first bladder panel 61 and second bladder panel 62 in orderto further raise the temperature of first bladder panel 61 and secondbladder panel 62. The temperature of mold 50 may vary depending upon thespecific materials utilized for first bladder panel 61 and secondbladder panel 62.

When formed into bladder 41 as depicted in FIG. 7, first bladder panel61 and second bladder panel 62 form bladder top hemisphere 66 andbladder bottom hemisphere 68, respectively. In addition, first bladderpanel 61 and second bladder panel 62 each form portions of seam 64. Thethickness of first bladder panel 61 and second bladder panel 62 prior tomolding may be greater than the thickness of the polymer materialforming bladder 41, as seen in the inset of FIG. 2. The rationale forthe difference in thickness between first bladder panel 61, secondbladder panel 62 and bladder 41 is that first bladder panel 61 andsecond bladder panel 62 may stretch during the thermoforming process.That is, the thickness differences compensate for thinning in firstbladder panel 61 and second bladder panel 62 that occurs when firstbladder panel 61 and second bladder panel 62 are stretched or otherwisedeformed during the formation of bladder 41.

Once first bladder panel 61 and second bladder panel 62 are positionedbetween mold portion 51 and mold portion 52 as depicted in FIG. 5A, moldportion 51 and mold portion 52 translate toward each other such thatfirst bladder panel 61 and second bladder panel 62 enter cavity 63 andare shaped and bonded, as depicted in FIG. 5B. As mold 50 contacts andcompresses portions of first bladder panel 61 and second bladder panel62, a fluid, such as air, having a positive pressure in comparison withambient air may be injected between first bladder panel 61 and secondbladder panel 62 to induce first bladder panel 61 and second bladderpanel 62 to respectively contact and conform to the contours of moldportion 51 and mold portion 52. Air may also be removed from the areabetween first bladder panel 61 and second bladder panel 62 and moldportion 51 and mold portion 52 through various vents, thereby drawingfirst bladder panel 61 and second bladder panel 62 onto the surfaces ofmold portion 51 and mold portion 52, respectively. That is, at least apartial vacuum may be formed between first bladder panel 61 and secondbladder panel 62 and the surfaces of mold 50. As the area between firstbladder panel 61 and second bladder panel 62 is pressurized and air isremoved from the area between mold 50 and first bladder panel 61 andsecond bladder panel 62, first bladder panel 61 and second bladder panel62 conform to the shape of cavity 53. More specifically, first bladderpanel 61 and second bladder panel 62 stretch, bend, or otherwise conformto extend along the surfaces of cavities 53 and form the general shapeof bladder 41. The final diameter of bladder 41 may be a variety ofsizes and chosen to enhance performance properties. In at least oneconfiguration, bladder 41 may have a diameter of about 24 mm and mayform the inner core layer 40 of golf ball 10 as discussed above.

In addition to shaping first bladder panel 61 and second bladder panel62, mold portion 51 and mold portion 52 compress first bladder panel 61and second bladder panel 62 together at locations corresponding withseam 64. More particularly, a ridge 54 extending around cavity 63 maycompress first bladder panel 61 and second bladder panel 62 together andform seam 64.

Once bladder 41 is formed within mold 50, mold portion 51 and moldportion 52 separate such that bladder 41 and peripheral portions offirst bladder panel 61 and second bladder panel 62 may be removed frommold 50, as depicted hi FIGS, 5C and 6. Bladder 41 is then permitted tocool, and a pressurized fluid may be injected into an interior ofbladder 41. Referring to FIGS. 3 and 4, mold portion 51 and mold portion52 are depicted as each including a channel 55 extending from areasforming cavity 53. During the thermoforming process discussed above,channels 55 form a conduit 63 that leads to bladder 41 at seam 64.Conduit 63 may be utilized to inject the pressurized fluid, and conduit63 may then be sealed at a position that corresponds with seam 64 toseal bladder 41, including the core substance 48 comprising thepressurized fluid, In addition, excess portions of first bladder panel61 and second bladder panel 62 may be trimmed or otherwise removed frombladder 41 along seam 64.

Once bladder 41 is formed to create core layer 40, intermediate layer 30and cover layer 20 may be applied using known techniques. For example, aresin, rubber or other composition as would be known in the art may besubsequently molded around bladder 41 to form intermediate layer 30.Once intermediate layer 30 is formed, cover layer 20, including innercover layer 22 and external cover 21, may be formed as is known in theart.

It should be understood that further manufacturing processes may beutilized to form a bladder core such as bladder 41 set forth herein, andthose skilled in the art will readily recognize such further processes.Examples of alternative processes that may be used for forming bladder41 include, but are not limited to, a blow molding process, aconventional rotational molding process, or by joining various bladderpanels by heat bonding or radio frequency bonding processes. Thesealternative techniques are discussed in U.S. Patent ApplicationPublication Number 2009/0325745, filed on Jun. 27, 2008, which is hereinincorporated by reference in its entirety.

A golf ball with a bladder core as set forth herein may also include aone-way valve to allow for adjustment of the pressurized fluid withinthe core. In the past, golfers have been unable to make adjustments to aspecific ball for different playing environments or to achieve certainplay characteristics. For example, a golfer might want to alter a ballfor play at a golf course at sea level in contrast with a golf course inthe mountains; for play during colder weather in contrast with playduring warmer weather; or for improving the performance of a ball for agolfer with a low golf club head speed.

FIGS. 8-9 depict a golf ball 100 which includes a pin-sized one-wayvalve 170 for adding pressure or releasing pressure from a bladder core140 contained within ball 100. Similar to the previously discussedembodiments, golf ball 100 may include a layered structure having (a) acover layer 120 that forms an exterior portion of golf ball 100, (b) anintermediate layer 130 and/or mantle shell located within cover layer120, and (c) an internal core 140. Similar to the embodiments describedabove, internal core 140 may be formed from a bladder 141 containing acore substance 148 that forms an interior portion of ball 100. Coverlayer 120 of golf ball 100 may also include both an outer cover layer121 and inner cover layer 122. Outer cover layer 121 of cover layer 120includes at least one dimple 124, and typically, a plurality of dimples124, which affect the flight characteristics of golf ball 100. Golf ball100 may be formed from the same materials previously discussed withrespect to golf ball 10. Furthermore, golf ball 100 may be altered in avariety of ways known to those of skill, such as by altering thecomposition of the materials used to form the ball or the number andthicknesses of the layers.

According to the embodiment depicted in FIGS. 8 and 9, golf ball 100 mayfurther include provisions for making adjustments to the pressurizedfluid or core substance 148. In at least one embodiment, golf ball 100may include a pin-sized one-way valve 170. One-way valve 170 may beconfigured as is known in the art, that is, one-way valve 170 may beconfigured such that a pressurized substance is held within bladder 141without escaping during normal play, yet may be adjusted using aninterfacing nozzle. In particular, as shown FIG. 9, one-way valve 170may include a nipple 171 that extends into bladder 141 and is capable ofinterfacing with a nozzle 172. Nozzle 172 may be attached to a hose 174which is ultimately attached to a pump. Nipple 171 allows for a fluid tobe introduced into bladder 141, or for a fluid to be withdrawn frombladder 141.

Bladder 141 may be formed using any one of the manufacturing processesset forth above in relation to the forming of bladder 41 of golf ball10. As one example, FIGS. 10A-12 set forth an exemplary method ofmanufacturing using the thermoforming process described above. Inparticular, FIGS. 10A-10B depict an exemplary thermoforming processusing the exemplary mold 50 depicted in FIGS. 3 and 4 and previouslydescribed. According to at least one embodiment, mold 50 may be utilizedto form bladder 141 from a pair of polymer sheets, bladder panel 161 andbladder panel 162, similar to the process described above with respectto golf ball 10. In particular, bladder panel 161 and bladder panel 162are positioned between upper mold portion 51 and lower mold portion 52,as depicted in FIG. 10A. In addition, according to at least oneembodiment, a one-way valve 170 may be placed between bladder panel 161and bladder panel 162 such that nipple 171 is positioned inside seamarea 164 and nozzle 172 extends through a conduit 163.

Thus, when formed into bladder 141 as depicted in FIG. 12, bladder panel161 and bladder panel 162 form bladder top hemisphere 166 and bladderbottom hemisphere 168, respectively. Further, one-way valve 170 may bepositioned between bladder panel 161 and bladder panel 162, andconfigured to protrude at seam 164.

During forming, once bladder panel 161 and bladder panel 162 arepositioned between mold portion 51 and mold portion 52 as depicted inFIG. 10A, mold portion 51 and mold portion 52 translate toward eachother such that first bladder panel 61 and second bladder panel 62 entercavity 63 around one-way valve 170 and are shaped and bonded, asdepicted in FIG. 10B, As mold 50 contacts and compresses portions ofbladder panel 161 and bladder panel 162, a fluid, such as air, having apositive pressure in comparison with ambient air may be injected betweenbladder panel 161 and bladder panel 162 to induce bladder panel 161 andbladder panel 162 to respectively contact and conform to the contours ofmold portion 51 and mold portion 52 as discussed above.

Once bladder 141 is formed within mold 50, mold portion 51 and moldportion 52 separate such that bladder 141, one-way valve 170 andperipheral portions of bladder panel 161 and bladder panel 162 may beremoved from mold 50, as depicted in FIG. 11. Bladder 141 is thenpermitted to cool, and a pressurized fluid or core substance 148 may beinjected into an interior of bladder 141 using one-way valve 170 orconduit 163. After bladder 141 is filled with core substance 148,conduit 163 may then be sealed at a position that corresponds with seam164 and around one-way valve 170 to seal bladder 141. In addition,excess portions of bladder panel 161 and bladder panel 162 may betrimmed or otherwise removed from bladder 141, leaving bladder 141 withone-way valve 170 as depicted in FIG.

12. Once bladder 141 is formed to create core layer 140, intermediatelayer 130 and cover layer 120 may be applied as above using knowntechniques.

It is further contemplated that a golf ball with a bladder core, such asdiscussed herein, may be further altered in various ways known to thoseskilled in the art and still fall within the spirit and scope of theinvention. For example, a skilled artisan may modify the number oflayers in the golf ball, alter the relative sizes of the layers, or thediameter of the core, alter the materials used on one or multiplelayers, change the dimple pattern, or perform another alternation knownin the art to enhance or alter performance characteristics of the ball.

FIG. 13 depicts a cross-sectional view of one such additionalembodiment, i.e., golf ball 200, having bladder core 240. As may be seenin FIG. 13, golf ball 200 exhibits a layered structure similar to thepreviously described embodiments, but with an additional layer, mantlelayer 250. In particular, according to one embodiment, golf ball 200 isdepicted as having (a) a cover layer 220 (with both an inner cover layer222 and an outer cover layer 221) that forms an exterior portion of golfball 200, (b) a mantle layer 250, where cover layer 220 substantiallysurrounds and encloses mantle layer 250, (c) an intermediate layer 230or outer core layer 230, where mantle layer 250 substantially surroundsand encloses outer core layer 230, and (d) an internal bladder core 240that forms an interior portion of ball 200, where outer core layer 230substantially surrounds and encloses core 240. Golf ball 200 may bemanufactured and formed in the same manner discussed above in relationto the previous embodiments, with the additional mantle layer 250 beingmolded or otherwise applied over intermediate layer 230 before coverlayer 220 is applied. The addition of mantle layer 250 may allow themanufacturer to add additional performance enhancements to golf ball200, such as increased distance and spin control off of the golf clubhead.

While various embodiments have been described herein, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of the presentdisclosure. Accordingly, the disclosure is not to be restricted exceptin light of the attached claims and their equivalents. Also, variousmodifications and changes may be made within the scope of the attachedclaims.

1-20. (canceled)
 21. A golf ball comprising: a core comprising abladder, the bladder having walls that define an internal space and thatcontain a fluid in the internal space, wherein the walls of the bladderare formed from layers of polymeric materials that are fused to eachother, wherein at least one layer of the bladder is formed ofethylene-vinyl alcohol copolymer and a layer adjacent to the at leastone layer of the bladder is formed of thermoplastic polyurethane; anintermediate layer substantially surrounding the core; and an outerlayer substantially surrounding the intermediate layer, the outer layerincluding a plurality of dimples.
 22. The golf ball according to claim21, wherein the intermediate layer comprises a rubber composition. 23.The golf ball according to claim 21, wherein the bladder comprises acenter layer of ethylene-vinyl alcohol copolymer.
 24. The golf ballaccording to claim 23, wherein the bladder further comprises layers ofthermoplastic polyurethane adjacent to the center layer.
 25. The golfball according to claim 24, wherein the thermoplastic polyurethanecomprises polyester-polyurethane.
 26. The golf ball according to claim21, wherein the bladder is formed from seven layers fused together. 27.The golf ball according to claim 26, wherein the seven layers comprise acenter layer of ethylene-vinyl alcohol copolymer and layers ofthermoplastic polyurethane adjacent to the center layer.
 28. The golfball according to claim 27, wherein the thermoplastic polyurethanecomprises polyester-polyurethane.
 29. The golf ball according to claim21, further comprising a one-way valve configured to interface with thebladder.
 30. The golf ball according to claim 21, further comprising amantle layer substantially surrounding the intermediate layer.
 31. Thegolf ball according to claim 21, wherein the fluid comprises apressurized gas.
 32. The golf ball according to claim 21, wherein thefluid is a pressurized gas.
 33. The golf ball according to claim 21,wherein the fluid is a liquid.
 34. The golf ball according to claim 21,wherein the walls of the bladder are formed from a plurality of bladderpanels joined together.
 35. The golf ball according to claim 34, whereina center layer of the bladder panels are formed of ethylene-vinylalcohol copolymer.
 36. The golf ball according to claim 35, wherein thebladder panels further comprises layers of thermoplastic polyurethaneadjacent to the center layer.
 37. The golf ball according to claim 36,wherein the thermoplastic polyurethane comprises polyester-polyurethane.38. The golf ball according to claim 34, wherein the bladder panels areformed from seven layers fused together.
 39. The golf ball according toclaim 38, wherein the center layer of the seven layers is a layer ofethylene-vinyl alcohol copolymer and layers adjacent to the center layerare made of polyester-polyurethane.
 40. The golf ball according to claim21, wherein the core is lighter in weight relative to other layers ofthe golf ball.